Overhead door construction



Feb. 16, 1965 c. R. WOLF ETAL 3,169,612

7 OVERHEAD DOOR CONSTRUCTION Filed July 5. 1960 2 Sheets-Sheet 1 INVENTORS: CECIL R. WOLF JOHN P. HOLLAND PAUL F SHARP 13 Q QM a 1 60 f? Z Feb. 16, 1965 c, R. WOLF ETAL 3,169,612

OVERHEAD DOOR CONSTRUCTION Filed July 5. 1960 2 Sheets-Sheet 2 INVENTORS: CECIL R. WOLF JOHN P; HOLLAND PAUL F. SwHARP United States Patent Ofiice 3,169,612 Patented Feb. 16, 1965 3,169,612 UVERI-EAD DOOR CONSTRUCTION Cecil R. Wolf and John P. Holland, Rock Falls, and Pan! F. Sharp, Sterling, 111., assignors to Frantz Manafacturing Company, Sterling, 111., a corporation of Illinois Filed July 5, 1960, Ser. No. 40,920 6 Claims. (Cl. 189-34) This invention relates to overhead door constructions and parts thereof, and particularly to improved door sections and improved frame members for lightweight overhead doors.

There is disclosed in our co-pending application Serial No. 834,174 filed August 17, 1959 for Overhead Door Construction an improved door for use in home installations such as garages, the door being formed in sections disposed horizontally and arranged one above the other and mounted for movement upon a track from a vertical door aperture closing position to a horizontal door aperture opening position. Each door section disclosed therein comprises a panel of plastic surrounded by frame members, the frame members being interconnected at the corners and including flanges to receive the edges of the plastic panel around the entire periphery thereof, the panel being held in position by a plurality of rivets.

It is an important object of the present invention to provide an improved construction of the door sections in overhead doors of the type set forth; more particularly, it is an object of the present invention to provide an improved joint between at least certain of the frazne members and the edges of the associated panel.

Another object of the invention is to provide an improved joint between the panel and frame member in a door section of the type set forth which is watertight whereby to prohibit water from gaining access to the rear of the door section either directly or by osmotic action in minute channels between the flanges of the door frame members and the panel. Yet another object of the invention is to provide an improved door construction of the type set forth wherein the use of rivets is eliminated in the horizontal frame members, the improved construction providing a stronger joint between the frame members and the panel.

In connection with the foregoing object, it is another object of the invention to provide a joint between at least certain of the frame members and the panel which can be more quickly formed during assembly, which is less expensive than constructions utilizing rivets, and which presents a smoother, neater streamlined appearance of the finished door section.

Still another object of the invention is to provide an improved joint between a frame member and the panel of a door section of the type set forth in which no apertures are formed in the frame members or the panel and in which the joint is continuous and not intermittent as is the case when the frame member and panel are joined by rivets as had been done heretofore.

A further object of the invention is to provide an improved frame member which is useful in combination with a panel to provide the above desired objects and advantages.

Further features of the invention pertain to the particular arrangement of the elements of the door section,

whereby the above outlined and additional operating features are obtained.

The invention, both as to its organization and method of operation together with further objects and advantages thereof will be better understood by reference to the following specification taken in connection with the accompanying drawings. In the drawings wherein like reference numerals have been utilized to designate like parts throughout;

FIGURE 1 is a front elevational view of an overhead door made in accordance with and embodying the principles of the present invention, the door being shown installed in the door aperture of a garage and placed in the closed position thereof;

FIG. 2 is an enlarged fragmentary view in perspective showing the joint between a frame member and the associated panel;

FIG. 3 is a further enlarged fragmentary view in Vertical section of that portion of the frame member enclosed within the dashed circle in FIG. 2, the frame memher being shown in the condition thereof before application to the associated panel;

FIG. 4 is a further enlargedfragmentary view in vertical section of that portion of FIG. 2 enclosed within the dashed circle; 7

FIG. 5 is an enlarged fragmentary view in perspective similar to FIG. 2 and illustrating a second embodiment of the present invention;

FIG. 6 is a further enlarged fragmentary view in vertical section of the portion of the frame member disposed within the dashed circle in FIG. 5, the frame member being shown in the condition thereof before application to the associated panel; and

FIG. 7 is a further enlarged fragmentary View in vertical section of the portion of FIG. 5 disposed within the dashed circle thereof.

There is shown in FIG. 1 of the drawings an overhead door 36 made in' accordance with and embodying the principles of the present invention. The door 3%) is shown mounted and disposed in a position to close the door opening or aperture in a garage 32, the aperture in the garage 32 being surrounded by the usual frame 34. It is to be understood that the door 39 is mounted on the usual tracks (not shown) for movement from the vertical position illustrated to close the door opening to a horizontal overhead position away from the door opening in the garage 32. Further details of the mounting structure for the door 3% can be found by referring to our copending application referred to above.

In the form of the invention illustrated herein, the door 36 is formed as four separate door sections arranged in horizontal position one above the other and interconnected by hinges (not shown), there being a top door section 48, two intermediate door sections 50, and a bottom door section 52. Each of the door sections includes a panel generally designated by the numeral 54 surrounded by a suitable frame; the panels 54 in each of the door sections are identical and only one will be described in detail with special reference to FIGS. 1 and 2. Each panel 54 extends the entire width of the door 3!) and therefore has a length substantially greater than the vertical extent thereof and comprises a substantially fiat body provided with three horizontally disposed ribs 58 and complementary grooves r recesses formed thereon including walls 60 disposed at an angle of approximately 75 with respect to the flat body of the panel 54. In a typical installation the panel 54 may have a thickness of 0.045 inch, the flat portion of the rib 58 may have a width of one inch, the total horizontal thickness of the panel 54 may be 1.1 inches and the panel may be 20 inches high and 18 to 20 feet long, if necessary. Preferably the panels 54 are formed of a compressible material such as synthetic organic plastic, for example, a polyester plastic suitably reinforced with nylon fibers and glass fibers to provide a shatterproof, light transmitting or translucent panel. Such a panel 54 is structurally strong, light in weight and flexible but provides a suitable door panel if provided with the proper frame. Such panels may be formed clear, translucent or opaque and may be colored, if desired. The ribs 58 increase the strength of the panel 54 without detracting from the appearance thereof and the flanges 56 along the top and bottom of the panel 54 are adapted to be engaged by the frame members. 7

Suitable framing is provided about the plastic panel 54 to provide the door sections 48, t) and 52, the frame for each of the three different door sections being also different as is set forth in the co-pending application identified above. The frame for the upper door section 48 includes a longitudinal top rail 62, a longitudinal upper joining rail 54, and two end rails 66. The door sections 50 are substantially identical, each being framed by a lower joining rail 140 along the upper edge thereof, upper joining rail 64 along the lower edge thereof and end rails 66 at the ends thereof. The lowermost section 52 is framed by a lower joining rail 14!) along the lower edge, a bottom rail 169 along the bottom edge thereof and two rails 66 along the side edges thereof. Only the lower joining rail 140 will be described in detail in the present specification and further details of construction of the upper rail 62, the upper joining rail 64, the bottom rail 16% and the end rails 66 can be obtained from the above identified co-pending application.

Referring to FIG. 2 of the drawing there is illustrated the lower joining rail 140, which forms the top frame member for the door sections 50 and 52, and the connection between the rail 14% and one of the associated plastic panels 54, the parts being shown on a slightly enlarged scale in vertical section. The lower joining rail 146 includes a horizontal wall 142 having an upwardly extending rear flange 144 and a downwardly extending rear flange 146 which is offset rearwardly with respect to the flange 144 when the parts are in the installed position illustrated in FIG. 1 of the drawing. A first front flange 148 is formed integral with the wall 142 and extends upwardly therefrom and has the end thereof curved rearwardly as at 150 to permit cooperation with a mating flange (not shown) on the upper joining rail 64. A first holding flange 152 is formed on the wall 142 to the rear of the flange 148 and a second downwardly extending holding flange 154 is formed forward of the flange 148 and spaced from the flange 152 to receive in the channel therebetween the flange 56 on the plastic panel 54, The flanges 144 and 148 are spaced apart a distance such that they will fit and lie between cooperating flanges onthe associated upper joining rail 64 (the flanges and the rail 64 not being illustrated).

Referring to FIG. 3 of the drawing it is further seen thatthe second holding flange 154 has a beveled surface 156 facing the flange 152, the beveled surface 156 being disposed, at an angle ofv approximately 35 with respect to the wall 160 of the flange 154 disposed toward the flange 1 52. The junction 158 between the surface 156 and the wall 166 provides a gripping member for engaging the associated flange 56 of the panel 54 as i s best seen in FIG. 4 of the drawings. More particularly, in assembling the panel 54 to the rail 149, the flange 56 is placed between the holding flanges 152 and 154 and the flange 154 is bent over or deformed such as by rolling whereby to push the outer edge of the flange 154 toward the flange 152 thereby causing the gripping member 158 to be placed against and partially embedded in the panel flange 55 thereby to press the other surface of the flange 55 against the first holding flange 152, so that the panel flange 56 is securely gripped and held between the holding flanges 152 and 154. The penetration of the gripping member 15:: into the flange 55 is made possible by forming the rail 149 of a material that is harder than the plastic panel 54 and to this end the rail 14% is formed of a malleable metal, the preferred material being aluminum.

The holding flanges 152 and 154 extend the entire ength of the rail as does the gripping member 158 and, accordingly, the joint illustrated in FIG. 4 of the drawing likewise extends the entire length of the rail 141 It has been found that the joint formed as illustrated in FIG. 4 is watertight and furthermore that the joint therein is capable of preventing movement of moisture up the front surface of the plastic flange 56 underneath the flange 154 and then down between the flange 152 and the plastic flange 56. Furthermore, the plastic flange 56 is securely held along substantially the entire length thereof instead of only at points as is the case when rivets are used to join the plastic flange 56 to the metal flange 152. As a result, the stresses holding the plastic panel 54 in place are distributed throughout the entire length thereof instead of being concentrated at rivet holes at spaced points. In addition, the method of forming the joint illustrated in FIGS. 2 and 4 is less expensive than the construction utilizing rivets and is much faster. The resulting joint is much smoother, neater and streamlined in appearance as well as providing a strong watertight assembly.

It is to be understood that the joint illustrated in FIGS. 2 and 4 can also be applied to the top rail 62, the upper joining rail 64 and the bottom rail 160 whereby to provide inexpensive, strong, watertight and attractive joints with the associated plastic panels 54. Preferably the end rails 66 are secured to the plastic panel 54 by the rivets 162, see FIG. 1.

A second embodiment of the invention is illustrated in FIGS. 5 to 7 of the drawings wherein like reference numerals have been applied to the plastic panel 54.

throughout. The frame member in the form of the rail 240 is similar to the rail 140 and more particularly includes a horizontal reinforcing wall 242 provided with an upwardly extending rear reinforcing flange 244 and a downwardly extending rear reinforcing flange 246 oflset rearwardly with respect to the flange 244 in the installed position. A first front flange 248 is formed integral with thewall 242 and extends upwardly therefrom and has the upper end 250 curved rearwardly to cooperate with the flanges on the adjacent frame member. A first downwardly extending holding flange 252 is formed on the wall 242 to the rear of the flange 248 and a second downwardly extending holding flange 254 is formed forward of the flange 248 and spaced from the holding flange 252 to receive in the channel therebetween the flange 56 of the plastic panel 54.

Referring to FIG. 6, the holding flanges 252 and 254 are shown in the condition thereof prior to assembly with the plastic panel 54. More particularly, it will be seen that the holding flange 254 extends at an angle of ap proximately 20 with respect to the holding flange 252 and is adapted to be moved to a position substantially parallel to the holding flange 252 during the assembly operation, see FIG. 7. Also formed on the wall of the holding flange 252 disposed toward the holding flange 254 is a pair of tooth-like ridges or gripping members 268 or 262 which extend the entire length of the associated holding flange 252 and are spaced apart and disposed substantially parallel to each other and the Wall 242. Three similar spaced apart tooth-like ridges or gripping members 264, 266, 268 are formed on the wall of the holding flange 254 disposed toward the holding flange 252, the gripping members 264, 266, 268 extending the entire length of the flange 254 and in the vertical position of the holding flange 254 (see FIG. 7) alternating with the gripping members 260 and 262, the gripping member 260 being disposed between the gripping members 264 and 266, the gripping member 266 being disposed between the gripping members 260 and 262 and the gripping member 262 being disposed between the gripping members 266 and 268.

To assemble the rail 240 on the associated panel 54, the panel flange 56 is first placed between the holding flanges 252 and 254 after which the holding flange 254 is moved from the position illustrated in FIG. 6 to that illustrated in FIG. 7 in any suitable manner such as by a suitable rolling operation applied to press the holding flange 254 towards the holding flange 252. In moving the holding flange 254 into the position illustrated in FIG. 7, the gripping members 260 to 268 are forced into the associated sides of the flange 56 thereby to grip and to hold the flange 56 therebetween. Since the toothlike projections 260 to 268 extend the entire length of the rail 240, this also serves to form a watertight connection between the plastic flange 56 and the rail 240, the joint having the same desirable characteristics as those set forth above with respect to the joint illustrated in FIG. 4 of the drawings.

It will be seen that there has been provided an overhead door structure and particularly an improved door section and an improved frame member and joint thereof with a compressible panel which fulfills all of the objects and advantages set forth above. Although two preferred forms of the invention have been illustrated in the drawings, it is intended to cover in the appended claims all such changes and modifications thereof as fall within the true spirit and scope of the invention.

We claim:

1. In an overhead door construction, the combination comprising a panel of compressible water-repellent material having a longitudinally extending flange thereon along the top and bottom edges thereof, a plurality of horizontal and vertical frame members surrounding said panel to provide a stiffening and reinforcing frame therefor, each horizontal frame member disposed adjacent to and engaging one of said longitudinally extending flanges on said panel including a longitudinally extending stiffenig wall disposed substantially perpendicular to the associated panel flange, a first longitudinally extending holding flange on said wall and extending therefrom substantially perpendicular thereto and generally parallel to said panel flange and disposed therebehind, a second longitudinally extending holding flange on said wall and extending therefrom in the same general direction as said first holding flange and spaced therefrom and generally parallel to said panel flange and disposed in front thereof, said first holding flange extending substantially beyond the longitudinal free edge of said second holding flange and providing a flat surface extending the length thereof for supporting thereon said panel flange throughout a substantial area thereof opposite the longitudinal free edge of said second holding flange, said first and second holding flanges being formed of a material having a hardness greater than that of said panel flange, and a gripping member on said second holding flange disposed toward said flat surface on said first holding flange and being pressed into and embedded in said panel flange and urging said panel flange against said flat surface on said first holding flange, whereby to form a strong and con tinuous and watertight joint between said gripping member and said panel flange.

2. The door construction set forth in claim 1, wherein said panel is formed of a synthetic organic plastic and said frame members are formed of aluminum.

3. In an overhead door construction, the combination comprising a panel of compressible water-repellent ma terial having a longitudinally extending flange thereon along the top and bottom edges thereof, a plurality of horizontal and vertical frame members surrounding said panel to provide a stiffening and reinforcing frame therefor, each horizontal frame member disposed adjacent to and engaging one of said longitudinally extending flanges on said panel'including a longitudinally extending stiffening wall disposed substantially perpendicular to the associated panel flange, a first longitudinally extending holding flange on said wall and extending therefrom substantially perpendicular thereto and generally parallel to said panel flange and disposed therebehind, a second longitudinally extending holding flange on said wall and extending therefrom in the same general direction as said first holding flange and spaced therefrom and generally parallel to said panel flange and disposed in front thereof, said first holding flange extending substantially beyond the longitudinal free edge of said second holding flange and providing a flat surface extending the length thereof for supporting thereon said panel flange throughout a substantial area thereof opposite the longitudinal free edge of said second holding flange, said first and second holding flanges being formed of a material having a hardness greater than that of said panel flange, the surface of said second holding flange disposed toward said first holding flange including a flat surface and the free edge of said second holding flange being beveled on the side thereof toward said first holding flange away therefrom to provide a beveled surface, and a gripping member provided by the inner section of said flat surface and said beveled surface on said second holding flange disposed toward said flat surface on said first holding flange and being pressed into and embedded in said panel flange and urging said panel flange against said flat surface on said first holding flange, whereby to form a strong and continuous and watentight joint between said gripping member and said panel flange.

4. The door construction set forth in claim 3, wherein the enclosed angle between said flat surface and said beveled surface on said second holding flange is about 5. In an overhead door construction, the combination comprising a panel of compressible water-repellent material having a longitudinally extending flange thereon along the top and bottom edges thereof, a plurality of horizontal and vertical frame members surrounding said panel to provide a stiffening and reinforcing frame therefor, each horizontal frame member disposed adjacent to and engaging one of said longitudinally extending flanges on said panel including a longitudinally extending stiffening Wall disposed substantially perpendicular to the associated panel flange, a first longitudinally extending hold ing flange on said wall and extending therefrom substantially perpendicular thereto and generally parallel to said panel flange and disposed therebehind, a second longitudinally extending holding flange on said Wall and extending therefrom in the same general direction as said first holding flange and spaced therfrom and generally parallel to said panel flange and disposed in front thereof, said first holding flange extending substantially beyond the longitudinal free edge of said second holding flange and providing a flat surface extending the length thereof for supporting thereon said panel flange throughout a substantial area thereof opposite the longitudinal free edge of said second holding flange, a tooth-like ridge on the free edge of said second holding flange and extending toward said flat surface on said first holding flange and being pressed into and embedded in said panel flange and urging said panel flange against said flat surface on said first holding flange, whereby to form a strong and continuous and watertight joint between said gripping member and said panel flange.

6. The door construction set forth in claim 5, wherein said second holding flange has an additional tooth-like ridge thereon parallel to said tooth-like ridge on the free edge thereof and having a flat surface between. said toothlike ridges, and at least one tooth-like ridge on said first holding flange substantially parallel to said tooth-like ridges on said second holding flange but oflset with respect thereto and disposed opposite said flat surface on said second holding flange.

References Cited by the Examiner UNITED STATES PATENTS 1,340,949 5/20 Goodrich. 1,545,875 7/25 Austin 20-56 2,543,612 2/51 Sylvan 2016 Q 2,805,450 9/57 Schlytern 160-235 X 2,880,796 4/59 Stroup 160232 2,969,618 1/61 Ratner e161. 1s9 34 2,993,572 7/61 RlCil 189-34 3,014,561 12/61 Rather Ct a1. 1s9 34 FOREIGN PATENTS 808,085 1/59 Great Britain.

RICHARD W. COOKE, JR., Primary Examiner.

EOSEPH D. BEIN, JOEL REZNEK, JACOB L. NACK- ENOPF, Examiners. 

1. IN AN OVERHEAD DOOR CONSTRUCTION, THE COMBINATION COMPRISING A PANEL OF COMPRESSIBLE WATER-REPELLENT MATERAIL HAVING A LONGITUDINALLY EXTENDING FLANGE THEREON ALONG THE TOP AND BOTTOM EDGES THEREOF, A PLURALITY OF HORIZONTAL AND VERTICAL FRAME MEMBERS SURROUNDING SAID PANEL TO PROVIDE A STIFFENING AND REINFORCING FRAME THEREFOR , EACH HORIZONTAL FRAME MEMBER DISPOSED ADJACENT TO AND ENGAGING ONE OF SAID LONGITUDINALLY EXTENDING FLANGES ON SAID PANEL INCLUDING A LONGITUDINALLY EXTENDING STIFFENING WALL DISPOSED SUBSTANTIALLY PERPENDICULAR TO THE ASSOCIATED PANEL FLANGE, A FIRST LONGITUDINALLY EXTENDING HOLDING FLANGE ON SAID WALL AND EXTENDING THEREFROM SUBSTANTIALLY PERPENDICULAR THERETO AND GENERALLY PARALLEL TO SAID PANEL FLANGE AND DISPOSED THEREBEHIND, A SECOND LONGITUDINALLY EXTENDING HOLDING FLANGE ON SAID WALL AND EXTENDING THEREFROM IN THE SAME GENERAL DIRECTION AS SAID FIRST HOLDING FLANGE AND SPACED THEREFROM AND GENERALLY PARALLEL TO SAID PANEL FLANGE AND DISPOSED IN FRONT THEREOF, SAID FIRST HOLDING FLANGE EXTENDING SUBSTANTIALLY BEYOND THE LONGITUDINAL FREE EDGE OF SAID SECOND HOLDING FLANGE AND PROVIDING A FLAT SURFACE EXTENDING THE LENGTH THERE- 